Railing support post with threaded receivers

ABSTRACT

A railing support post with threaded holes or receivers for receiving threaded hardware, such as might be used for tensioned cable railing. A decorative sleeve or post cover may be used to at least partially enclose the railing support post. The railing support post may be manufactured, for example, by providing an elongated member of a prescribed length, drilling a plurality of holes spaced along the length of the elongated member, and tapping the plurality of holes to form a plurality of threaded receivers. The threaded receivers are configured to receive rail fittings or other fittings.

PRIORITY CLAIM

This application is a continuation application of U.S. application Ser.No. 14/795,238 filed on Jul. 9, 2015 entitled “Railing Support Post withThreaded Receivers” now U.S. patent Ser. No. 10/006,222, which is acontinuation of U.S. application Ser. No. 14/308,013 filed on Jun. 18,2014 entitled “Railing Support Post with Threaded Receivers” now U.S.Pat. No. 9,126,289, which is a continuation-in-part application of U.S.application Ser. No. 13/934,566 filed on Jul. 3, 2013 entitled “RailingSupport Post with Threaded Receivers” now U.S. Pat. No. 8,814,145, whichclaims the benefit of Provisional Application 61/668,678 filed on Jul.6, 2012 entitled “Cable Railing System,” and Provisional Application61/824,445 filed on May 17, 2013 entitled “Structural Post with ThreadedReceivers”. The subject matter of the aforementioned applications ishereby incorporated by reference.

BACKGROUND

The use of decorative post covers and columns has become increasinglypopular in the railing industry. The post covers and columns are oftenused to cover unattractive metal fittings and connectors for cablerailing or other types of railings. Traditionally, a wood post, such asa 4″×4″ post, for example, has been used to transfer railing structuraland force components to the deck or surface on which the inner post isattached, and a decorative wood, fiberglass, PVC or composite sleeve isplaced over the inner wood post.

In keeping with such decorative columns or sleeves being decorative,they often do not provide very much mechanical strength or integrity tothe railing systems in which they are employed, often being columns orsleeves made of composite materials or fiberglass. Additionally, cablerailings are typically lagged into wood posts internal to the decorativesleeve or column, in a labor intensive process requiring the use ofexpensive hardware and a structural post abutting the column.

BRIEF DESCRIPTION OF THE DRAWINGS

Example embodiments of the present disclosure will be described belowwith reference to the included drawings such that like referencenumerals refer to like elements and in which:

FIG. 1 is a diagrammatic representation of railing support post,consistent with certain embodiments;

FIG. 2 is a diagrammatic representation of a decorative sleeve for arailing support post, consistent with certain embodiments;

FIG. 3 is a diagrammatic representation of a decorative sleeve cap for arailing support post, consistent with certain embodiments.

FIG. 4 is a cross-sectional view of an assembly of a railing supportpost, a decorative sleeve, and a decorative sleeve cap, consistent withcertain embodiments;

FIG. 5 is a cross-sectional view of an assembly of a railing supportpost, a decorative sleeve, a decorative sleeve cap and an exemplary railfitting, consistent with certain embodiments;

FIGS. 6A and 6B are further cross-sectional views of an assembly of arailing support post, a decorative sleeve and exemplary rail fitting,consistent with certain embodiments;

FIG. 7 is a cross-sectional view of an assembly of a railing supportpost, a decorative sleeve, a decorative sleeve cap and an exemplary railfitting, consistent with certain embodiments;

FIG. 8 is a view of a railing assembly utilizing two railing supportposts, consistent with certain embodiments;

FIG. 9 is a flow chart of a method for manufacturing a railing supportpost, consistent with certain embodiments;

FIG. 10 is a diagrammatic representation of a base support plate,consistent with certain embodiments;

FIG. 11 is a view of the section 11-11 shown in FIG. 10;

FIG. 12 is a diagrammatic representation of a cross-sectional view of alower portion of a cable railing support post assembly, consistent withcertain embodiments;

FIG. 13 is a diagrammatic representation of a lower portion of a cablerailing support assembly viewed from above, consistent with certainembodiments;

FIG. 14 is a view of the section 14-14 shown in FIG. 13;

FIG. 15 is a diagrammatic representation of an upper plate of a basesupport bracket of a cable railing support post viewed from above,consistent with certain embodiments;

FIG. 16 is a side view of the upper plate shown in FIG. 15; and

FIG. 17 is a diagrammatic representation of a lower portion of a cablerailing support post assembly, consistent with certain embodiments.

DETAILED DESCRIPTION

For simplicity and clarity of illustration, reference numerals may berepeated among the figures to indicate corresponding or analogouselements. Numerous details are set forth to provide an understanding ofthe embodiments described herein. The embodiments may be practicedwithout these details. In other instances, well-known methods,procedures, and components have not been described in detail to avoidobscuring the embodiments described. The description is not to beconsidered as limited to the scope of the embodiments described herein.

The terms “a” or “an”, as used herein, are defined as “one” or “morethan one”. The term “plurality”, as used herein, is defined as “two” or“more than two.” The term “another”, as used herein, is defined as atleast a second or more. The terms “including” and/or “having”, as usedherein, are defined as comprising (i.e., open language). The term“coupled”, as used herein, is defined as connected, although notnecessarily directly, and not necessarily mechanically.

Reference throughout this document to “one embodiment”, “certainembodiments”, “an embodiment”, “an example”, “an implementation”, “anexample” or similar terms means that a particular feature, structure, orcharacteristic described in connection with the embodiment, example orimplementation is included in at least one embodiment, example orimplementation of the present invention. Thus, the appearances of suchphrases or in various places throughout this specification are notnecessarily all referring to the same embodiment, example orimplementation. Furthermore, the particular features, structures, orcharacteristics may be combined in any suitable manner in one or moreembodiments, examples or implementations without limitation.

The term “or” as used herein is to be interpreted as an inclusive ormeaning any one or any combination. Therefore, “A, B or C” means “any ofthe following: A; B; C; A and B; A and C; B and C; A, B and C”. Anexception to this definition will occur only when a combination ofelements, functions, steps or acts are in some way inherently mutuallyexclusive.

In accordance with the various embodiments described herein there isprovided a railing support post with pre-threaded, pre-drilled receiversor inserts, or threaded holes that provides not only structural supportto a decorative sleeve that may be placed over it, but by havingthreaded receivers additionally provides a quick and easy way to connectrailing fittings to the railing support post. An exemplary embodiment isshown in FIG. 1. The railing support post 100 includes an elongatedmember 102 having rows of threaded receivers 104, 106 spaced along thelength of the elongated member. In FIG. 1, the elongated member 102 hasa first line of threaded receivers 104 in a first face or side ofelongated member 102 and a second line 106 in a second face or side ofelongated member 102. The other faces of the elongated member may alsoinclude threaded receivers. The threaded receivers are configured toreceive rail fittings suitable for cable railings, but may be usedalone.

The elongated member 102 has sufficient strength to support railings,handrails or other fittings, coupled via the threaded receivers 104,106, to it. The threaded holes or receivers 104, 106 of the railingsupport post 100 are spaced in accordance with spacing of railing to beattached to it and so can support industry standard railing. The postheight may correspond to an industry standard height, such as 36 inchesfor residential use and 42 inches for commercial use, for example. Thus,the railing support post 100 may be a 36 inch residential post or a 42inch commercial post. It will be understood that railing support postsof varying heights may be used without departing from the spirit andscope of the described embodiments. For example, a shorter railingsupport post could be mounted on a knee wall, while a longer railingsupport could be mounted with a column or side-mounted on a facia.

The railing support post may be made of metal, such as stainless steel,aluminum, bronze, or other metal material, or composite material such asmaterial with carbon fibers, etc., with pre-threaded holes or receivers,thereby allowing cables or other railings of a railing system to beattached via standard stainless steel or other known hardware andfitting options to this railing support post. The threaded receivers104, 106 of the railing support post 100 may be evenly spaced threadedholes (such as vertically to meet code) that are used when cable infillis needed or desired.

While the railing support post is illustrated as being substantiallyrectangular in shape, it is not so limited and may in fact be at leastpartially round or other shapes. Here, the term “rectangular” is definedto include “square”.

As described below, a separate bracket may be used for the graspablehandrail when desired or needed, as for a 42 inch commercialapplication, for example.

The railing support post may be mounted to a variety of surfaces, suchas decking, stairs, flooring, etc. To facilitate mounting, a base 108may be fixed to the lower end of the elongated member 102. One or moreholes 110 in the base may be provided for fasteners.

The railing support post 100 also includes a sleeve support 110 coupledto the elongated member 102, the sleeve support 110 is configured tosupport a decorative sleeve such that the elongated member is located inthe interior of decorative sleeve. The sleeve support 110 may includeone or more threaded holes 112 to enable coupling of the post 100 to adecorative sleeve and/or a handrail.

When used for guardrail protection or with hand rails together withhollow composite sleeves, the railing support posts allow for cables tobe attached from any direction. Thus, the railing support post may be anend post, a corner post, an intermediate post, etc. The railing supportpost may then work in concert with other posts of an overall railingsystem. For example, intermediate posts may be used in long sections ofrailing or fencing, where cable railing passes straight through theintermediate posts, or may operate independent of other posts.Accordingly, threaded receivers may be located on one or more sides andmay be used to receive rail fittings or to allow passage of a cablerail. In one embodiment, threaded receivers are located on four sides ofthe elongated member.

FIG. 2 is a diagrammatic representation of a decorative sleeve or postcover 200 configured to at least partially enclose a railing supportpost. The decorative sleeve 200 may be constructed of a light-weight,non-structural material, such as PVC or fiberglass. One or more holes202 may be provided to allow railing fittings to pass through the sleeveto threaded receivers in the interior railing support post. Additionalholes 204 may be provided to enable coupling of the decorative sleeve200 to a sleeve support of the railing support post.

The decorative sleeve may be provided without holes 202 and 204. Theholes may be added, as needed, during installation of a railingassembly. To facilitate installation, a drill-hole template may beprovided to indicate where holes may be drilled in the decorative sleeveso as to align with the threaded receivers in the elongated member. Thetemplate, support post, decorative sleeve and other components may beprovided as a kit.

In an exemplary embodiment, the elongated member has a substantiallysquare cross-section, with outside width approximately 2 inches. In afurther embodiment the outside width is in the range 1-3 inches. Largeror smaller widths may be used without departing from the presentdisclosure.

The elongated member may have a solid, hollow, U-shaped, L-shaped,T-shaped, H-shaped, I-shaped, round, rectangular or other cross-section.The elongated member may be constructed of a thin-walled material, suchas ⅛″, 3/16″, ¼″ or 5/16″ metal. Other materials and materialthicknesses may be used, provided the railing support post hassufficient strength to support one or more railings.

In an exemplary embodiment, the decorative sleeve has a substantiallysquare cross-section, with outside width approximately 5 inches. In afurther embodiment the outside width is in the range 4-6 inches. Largeror smaller widths may be used without departing from the presentdisclosure.

The decorative sleeve 200 is sized to pass over the elongated member andthe base support bracket of the railing support post.

In an exemplary embodiment, the base support bracket of the railingsupport post is substantially square, with width approximately 4.2inches. In a further embodiment the outside width is in the range 2-7inches. Larger or smaller widths may be used without departing from thepresent disclosure.

FIG. 3 is a diagrammatic representation of a decorative sleeve cap 300configured to be located on top of a decorative sleeve. In a furtherembodiment, the decorative cap 300 is integral with the decorativesleeve. A variety of cap styles will be apparent to those of ordinaryskill in the art. In some embodiments, the cap is integrated with thedecorative sleeve.

FIG. 4 is a vertical, cross-sectional view through an assembly of arailing support post 102, a decorative sleeve 200 and a decorativesleeve cap 300, in accordance with one or more embodiments. Variousembodiments of threaded receivers 106 are shown by way of explanation.In practice, a railing support post may contain a single type ofthreaded receiver. Receiver 106 a comprises a front-plate, with both thefront-plate and elongated member 102 being threaded. Receiver 106 bcomprises a simple threaded hole in the elongated member 102. Receiver106 c comprises a threaded insert. Receiver 106 d comprises a threadedflow-drilled hole. Receiver 106 e comprises a threaded front-plate.Other types of threaded receivers will be apparent to those of ordinaryskill in the art.

In the example embodiment shown, the railing support post is coupled toa surface 402 using fasteners 404. Various types of fasteners may beused.

Railing fittings that are configured to be placed in tension may bepassed through holes 202 in the decorative support sleeve 200 andscrewed into threaded receivers 106 of the railing support post.Fittings that require a mating surface may be coupled via a spacer, suchas hollow spacer 406 that rests against the elongated member 102. Spacer406 provides an external mating surface and is sized to span the gapbetween the elongated member 102 and the exterior of the decorativesleeve 200, passing through a hole in the decorative sleeve 200. Thespacer 406 is adapted to protect the decorative sleeve from compressiveloads when a rail fitting is coupled to the threaded receiver of theelongated member. Spacer 406 may also be used, for example, when a cablerail is angled diagonally up or down, as for a step or stair railing toprevent loading of the decorative sleeve.

The decorative sleeve 200 may be attached to the sleeve support 112 ofthe railing support post via a fastener 408.

Together, the decorative sleeve 200 and support cap 300 enclose therailing support post 300.

The railing support post allows for the tensioning of cables to betransferred to the surface of the railing support post inside adecorative sleeve, thereby allowing the decorative sleeve or shell tobecome lighter and more decorative.

A top handrail or guard rail may be bolted directly to the railingsupport post using the threaded holes in the top sleeve support 112. Inone example embodiment, the sleeve support 112 comprises square tubing,such as 1 inch square, for example. This will accommodate all anglesthat a standard stair arrangement might use. The sleeve supports 112 maybe attached at one or more positions on the elongated member. The sleevesupport may be pre-attached, by welding or bonding for example, or maybe attached using fasteners. The sleeve support is sized to accommodatethe decorative sleeve to be used.

A grab-rail 410 may be attached to the railing support post via spacer406 and bracket 412. A threaded fastener 414 passes through the spacer406 and the threaded portion 416 of the fastener screws into a threadedreceiver of the elongated member 102. An additional hollow spacingelement 418 may be used to provide a stand-off. Optionally, elements 406and 418 may be combined as a single spacer that enables the bracket 412to be coupled to the elongated member 102 without loading the decorativesleeve 200.

In a further embodiment, the sleeve support is integrated with thedecorative sleeve. In a still further embodiment, the decorative cap isintegrated with the decorative sleeve. In a still further embodiment,the sleeve support, the decorative sleeve and the decorative cap areintegrated. For example, the sleeve support, the decorative sleeve andthe decorative cap may be molded as a single plastic part.

FIG. 5 is a vertical, cross-sectional view through an assembly of arailing support post 102, a decorative sleeve 200, a decorative sleevecap 300 and exemplary railing fittings, in accordance with variousembodiments. A horizontal guardrail 502 may be coupled to the sleevesupport 112. Mechanical loads placed on the guardrail 502 are carried bythe elongated member 102 of the railing support post rather than by thedecorative sleeve 200. A grab-rail 410 may be coupled to the elongatedmember by a support bracket 506. In the example shown, the supportbracket 506 has a flange that is mounted to the elongated member 102using two threaded receivers. In one example embodiment, the attachmentpoint of the bracket 506 may be located approximately one fourth of theway between the flange holes and/or may be invertible to allow for avariety of handrail heights. By way of illustration, the grab-rail 410and support bracket 506 are depicted as being coupled to the right ofthe elongated member 102. However, the grab-rail 410 and support bracket506 may be coupled to the front or back face of the elongated member 102so as to provide a grab-rail 410 running parallel to the cable sections508.

Cable sections 508 may be attached to the threaded receivers 106 of therailing support post using fittings 510. The fittings 510 have athreaded section 512 that may be screwed in a threaded receiver to holdthe cable section 508 in tension. The fittings 510 pass through thedecorative sleeve 200 but are not supported by it. Thus, the decorativesleeve 200 may be constructed of various light weight decorativematerials.

The fittings 510 may have two threaded ends 512. One threaded end of afitting may have left-hand thread and the other end a right-hand threadto facilitate tensioning. One threaded end allows coupling to a cablerail while the other threaded end 512 allows coupling to the elongatedmember 102. Tension in the cable section 508 may be adjusted by rotatingthe body of the fitting. Rotation may be facilitated by a hexagonal,square, or flattened section of the fitting.

FIG. 6A is a partial, cross-sectional view through an assembly of arailing support post 102, a decorative sleeve 200 and exemplary railingfittings, in accordance with various embodiments. A cable section 508 ispasses through a flow-drilled hole 106 in the decorative sleeve or postcover 200 and is coupled to the elongated member 102. Insert 602 may bescrewed on the threaded portion 512 of the rail fitting 510 andfunctions to protect the decorative sleeve 200 surround the fitting andto enhance appearance of the assembled railing. The fitting may beprovided with a hexagonal, square, or flattened section 604 tofacilitate tensioning of the cable section 508. Other types of fittingswill be apparent to those of ordinary skill in the art.

In FIG. 6A, the wall thickness of decorative sleeve or post cover 200 isdepicted as being thinner than the wall thickness of the elongatedmember 102. However, other wall thicknesses may be used withoutdeparting from the present disclosure. For example, FIG. 6B is apartial, cross-sectional view through an assembly of a railing supportpost 102, a decorative sleeve 200 and exemplary railing fittings, inaccordance with an embodiment. In this embodiment, the wall thickness ofdecorative sleeve or post cover 200 is depicted thicker than the wallthickness of the elongated member 102.

FIG. 7 is a cross-sectional view of an assembly of a railing supportpost 100, a decorative sleeve 200, a decorative sleeve cap 300 andexemplary rail fittings 510, consistent with certain embodiments. Thebase support bracket 108 is fastened to the surface 402 using fasteners404. The decorative sleeve 200 is placed over the elongated member 102of the railing support post 100, and decorative cap 300 is installed.Guard rails 502 are attached to the sleeve support 112 of the railingsupport post using fasteners 408. In the embodiment shown, the cablerails 508 extend through threaded receivers 106 the elongated member 102and holes 202 in the decorative sleeve 200 to emerge on the oppositeside of the decorative sleeve. In this way, the cable rails 508 cancontinue through one or more railing support posts to extend the rail.In addition, a variety of rail fittings may be used. The rail fittingmay be configured to facilitate screwing the fitting into a threadedreceiver to apply tension to the attached cable rail.

In the embodiment illustrated in FIG. 7, the decorative cap 300 isincorporated with the decorative sleeve 200. In addition, the elongatedmember may be embedded in the decorative cap to provide the sleevesupport.

The railing support post may also be used in conjunction with many kindsof lighting fixtures, should the need arise.

A wide variety of materials may be used for each of the variouscomponents, fixtures, and elements described herein, including aluminum,stainless steel, steel, wood, cast aluminum, brass, bronze, aluminumbronze, nickel aluminum bronze, nick bronze, carbon fiber, and plastic,as well as cast, extruded or extrusion parts.

FIG. 8 is a view of a railing assembly using two railing support posts,consistent with certain embodiments. The first railing support post 100a is located in a decorative sleeve 200 a that take the form of a pillarthat extends from floor 402 to ceiling 802. A cable 804 may be stretchedbetween the floor 402 and the ceiling 802 to help support the railingsupport post 100 a and help meet hurricane “lift-off” requirements. Asecond railing support post 100 b is fastened to the floor 402. Therailing support post 100 b may be fastened using a base support bracket,a cable fastened to the floor, or a combination thereof. The railingsupport post 100 b is covered by a decorative sleeve 200 b and adecorative cap 300. A guard rail 502 is coupled to the first railingsupport post 100 a via bracket 506 and to the second railing supportpost via sleeve support 112. A number of cable rails 508 are stretchedbetween the two railing support posts. The cable rails 508 are coupledto the railing support posts using fittings 510 that screw into threadedreceivers of the railing support posts. The fittings 510 enable thetension in the cable rails to be adjusted. The tension is supported bythe railing support posts 100 a and 100 b so that the decorative sleeves200 a and 200 b can be constructed of light-weight decorative materials.The height of the guard rail 502 and the spacing between cable rails 508may be selected to meet building codes. The cable rail spacing may bepredetermined, so that the threaded receivers can be fabricated when thesupport post is manufactured, thereby minimizing the installation timeof a railing assembly.

In an exemplary embodiment, the threaded receivers are evenly spaced atapproximately 3.09 inch spacing. However, other spacing may be used.

FIG. 9 is a flow chart 900 of a method for manufacturing a rail supportpost, in accordance with certain embodiments of the disclosure.Following start block 902, an elongated member of a desired length isprovided. The desired length may correspond to a standard lengthspecified in a building codes, or may be a custom length. At block 906 aplurality of holes are drilled in the elongated member. The holes arespaced in a row along the length of the elongated member. Rows of holesmay be place on some or all sides of the elongated member. The elongatedmember may have a hollow or solid cross-section. When a hollow orangular cross-section is used, the holes may be drilled usingflow-drilling, so as to increase the thickness of the elongated memberin the vicinity of the hole and provide an increased thread length. Thisapproach allows thinner materials to be used without the use of front-or back-plates to increase the thread length. However, other methods maybe used to create the holes, such as conventional drilling, lasercutting, punching, etc. The holes are tapped at block 908 to form aplurality of threaded receivers. The threaded receivers are configuredto receiver rail fittings due use, and may be fabricated by other means.

At block 910, a base support bracket is prepared. In one embodiment, thebase support bracket is made by cutting the bracket from a sheet ofmetal and drilling or cutting holes in it to enable it to be attached toa mounting surface. Optionally, a lower sleeve support may beincorporated. In one embodiment this may be done by machining one ormore steps in the block to form one or more raised platforms sized tofit inside a hollow decorative sleeve placed over the post. In a furtherembodiment, one or more upper plates may be added in a stack to form oneor more raised platforms, again sized to fit inside a hollow decorativesleeve placed over the post. The edges or corners of an upper plate maybe bent upwards to guide the plate(s) inside the decorative sleeve.

At block 912, a base support bracket is attached to an end of theelongated member, the base support bracket being configured to enablethe elongated member to be fastened to a surface when in use. The basesupport bracket may be attached by welding or bonding, for example.

At block 914, a sleeve support is attached to the elongated member. Thesleeve is configured to provide support for a decorative sleeve that, atleast partially, encloses the elongated member in use. The sleevesupport may be attached by welding or bonding, for example. Themanufacture terminates at block 916.

Additional manufacturing steps may be performed. For example, if thesupport post is constructed of stainless steel, a passivation step maybe included. For other materials, an anti-corrosion coating may beapplied, for example.

As described above a cable rail support post may be produced by aprocess comprising: providing an elongated member having one or morewalls, flow-drilling a number of holes in at least one walls of theelongated member, the holes spaced along a length of the elongatedmember. Flow-drilling a hole increases the thickness of the wall in thevicinity of the hole. The flow-drilled holes are tapped to producemultiple threaded receivers spaced along a length of the elongatedmember, that can be used to receive cable rail fittings. A base supportbracket is attached to a lower end portion of the elongated member, thebase support bracket configured to enable the cable rail support post tobe fastened to a surface. A sleeve support may be joined to theelongated member, at the upper or lower end portion, for example, thesleeve support adapted to support a decorative sleeve that at leastpartially encloses the elongated member. In one embodiment, the basesupport bracket is welded to the first end portion of the elongatedmember.

The base support bracket may have one or more raised platforms, eachraised platform sized to match an interior dimension of a hollowdecorative sleeve. The platforms may be produced by machining or castingone or more steps may be machined or cast around a perimeter of the basesupport bracket. In a further embodiment, two or more plate elements ofdifferent sizes are joined in a stack to produce the base supportelement. The plates may be cut from sheet metal.

In one embodiment, the base support bracket comprises a lower plate andan upper plate. The lower plate is joined to and supports the lower endportion of the elongated member. The lower plate has a first set ofholes to enable the cable rail support post to be attached to a surface.The upper plate is sized to match an interior dimension of a hollowdecorative sleeve, and is mountable on the lower plate such that asecond set of holes in the upper plate aligns with first set of holes ofthe lower plate. The lower plate is adapted to support a decorativesleeve passed over the elongated member.

Optionally, at least one side portion of the upper plate is bent upwardsto facilitate alignment of a hollow decorative sleeve around the upperplate.

The lower plate may be cut from sheet metal of a first thickness, whilethe upper plate is cut from sheet metal of a second thickness, thesecond thickness less being than the first thickness.

A lateral dimension of the base support bracket may be approximately 4″and a thickness of the base support bracket may be greater than 5/16″ incertain embodiments. The base support bracket may be approximatelysquare, or another shape.

In one embodiment, the elongated member is made of metal and has a wallthickness of between 1/16″ and ⅜″.

The cable rail support post may be manufactured by providing anelongated member having one or more walls, providing a base supportbracket, and forming a set of threaded receivers spaced along a lengthof the elongated member. A threaded receiver may be produced byflow-drilling a hole in the elongated member, where the flow drillingincreases the thickness of the wall in the vicinity of the hole, andtapping the flow-drilling hole. Two or more mounting holes are made inthe base support bracket and the base support bracket is welded to anend of the elongated member. The threaded receivers are configured toreceive rail fittings.

The base support bracket and the mounting holes may be cut from a sheetof metal having a thickness between ¼″ and ¾″, and one or more steps maybe machined around a perimeter of a plate element to provide one or moreraised platforms, each raised platform being sized to match an interiordimension of a hollow decorative sleeve. Alternatively, the base supportbracket may be made by casting a plate element having one or more stepsaround its perimeter, each raised platform being sized to match aninterior dimension of a hollow decorative sleeve.

In a further embodiment, the base support bracket is made by joining twoor more plate element of different sizes in a stack to provide one ormore raised platforms, each raised platform being sized to match aninterior dimension of a hollow decorative sleeve.

FIG. 10 is a diagrammatic representation of a base support plate,consistent with certain embodiments. Referring to FIG. 10, the basesupport bracket 108 has a number of holes 110 that enable the bracket tobe attached to a mounting surface, such as deck or floor, using fixingssuch bolts or screws that pass through the holes. An additional hole1002 may be included to allow for drainage of water from the interior ofthe post. A number of steps 1004 are provided such that the bracketcomprises a number of raised platforms of different sizes. Thedimensions of the platforms, indicated by the arrows 1006 for example,are selected to correspond to or be just less than the interiordimension of a hollow decorative sleeve placed over the post. Thedecorative sleeve is discussed in more detail above. In one embodiments,a single raised platform may is used. In a further embodiment, a seriesof platforms are used to accommodate decorative sleeves with differentinternal dimensions.

In one embodiment, the base 108 is approximately 4″ square, the upperraised platform is approximately 3.66″ square, the middle raisedplatform is approximately 3.77″ square and the lower raised platform isapproximately 3.83″ square. However, it will be apparent to those ofordinary skill in the art that other dimensions may be used.

In FIG. 10, the raised platforms are substantially square. However,other shapes may be used, such as elliptical, circular, triangular, etc.

FIG. 11 is a view of the section 11-11 shown in FIG. 10. The basesupport bracket has a number of steps 1004 that form a number of raisedplatforms. The base support bracket may be produced by machining thesteps in a metal plate or by casting. Machining may be performed by aknown process, such as turning, milling, planing, shaping, broaching,grinding, ultrasonic machining, chemical machining, electrical dischargemachining, electrochemical machining, high-energy beam machining, etc.

In one embodiment, the height of the steps is approximately 1/16″. In afurther embodiment the height of the steps is greater than 1/16″.

FIG. 12 is a diagrammatic representation of cross-section of a lowerportion of a cable railing support post assembly, consistent withcertain embodiments. The assembly includes the elongated member 102 andthe base support bracket 108 that form the cable rail support post. Thebase support bracket is attached to surface 402 using fixing 404 thatpasses through a hole 110 in the bracket. In practice, fixings 402 wouldbe placed in two or more of the holes 110. The assembly also includes ahollow decorative sleeve 200 that passes over the elongated member 102and rests on a step 1104 of the base support bracket 108. In the exampleshown, the sleeve rests on the lower step. Sleeves with smaller internaldimension 1204 might rest on a different step. A decorative collar 1206may be placed around the base of the support post and sleeve to hide theedges of the base support bracket 108 and the lower end of the sleeve200. In this example, hole 1208 is aligned with hole 1002 to providedrainage. In this example, the raised platforms are integral to (partof) the base support bracket and provided a lower support for thedecorative sleeve 200.

FIG. 13 is a diagrammatic representation of a lower portion of a cablerailing support assembly viewed from above, consistent with certainembodiments. In this embodiment, the base support 108 includes a lowerplate 1302 that is attached to the elongated member 102, and an upperplate 1304 that provides a lower support for the decorative sleeve. Thelower plate 1302 has sufficient strength to provide structural supportfor the post. In one embodiment, the plate is approximately ⅜″ thick. Infurther embodiments, the plate thickness is as little as ¼″, but may bethicker, such as approximately ½″, ¾″ or 1″. The thickness may beselected according to the material of the base support bracket and/orthe height of the post.

The upper plate 1304 may have a central cut-out 1308 with sufficientwidth 1306 to enable it to be positioned before or after the elongatedmember 102 is joined to the base support bracket 108. The upper plate1304 also has a number of holes 1301 that align with corresponding holesin the lower plate 1302. The dimension 1006 of the upper plate isselected to mate with an internal dimension of a decorative sleeve.Thus, in use, the upper plate prevents lateral motion of the decorativesleeve. The upper plate may be joined to the lower plate duringmanufacture, or may be supplied separately and held in place by the basesupport bracket fixings. More than one upper plate may be stacked toallow for decorative sleeves of different internal dimensions.

FIG. 14 is a view of the section 14-14 shown in FIG. 13. This viewillustrates how the combination of the lower plate 1302 and the upperplate 1304 form a step 1004 and a raised platform 1304. Hole 1002 isopen to the interior of the elongated member 102 to provide drainage.

FIG. 15 is a diagrammatic representation of a further upper plate of abase support bracket of a cable railing support post viewed from above,consistent with certain embodiments. In this embodiment, the upper plate1304 is cut from a sheet of metal. Holes 1310 and central cut-out 1308may be cut during the same process step. The corners 1502 of the plateare bent upwards to positions 1502′ at approximately 90° to the plate.The cutting and bending may be performed in a single stamping process oras separate processes. In one embodiment, perforations are cut along thebend lines to facilitate bending during manufacture or bending at alater time, such as the time of installation.

FIG. 16 is a side view of the upper plate shown in FIG. 15. This viewshows the corner 1502′ at approximately 90° to the lower portion of theplate. The corners function as guides for a decorative sleeve as it ispassed over the support post and prevent lateral motion of thedecorative sleeve once it is positioned.

FIG. 17 is a diagrammatic representation of a lower portion of a cablerailing support post assembly, consistent with certain embodiments. Asdescribed above, the corners 1502′ function as guides for a decorativesleeve 200 as it is passed over the support post 102 and prevent lateralmotion of the decorative sleeve 200 once it is positioned. The materialof the upper plate 1304 may be selected to allow for manual flexing ofthe corners 1304 to accommodate manufacturing variability in thedecorative sleeves. Fixings 404 pass through aligned holes 1310 in theupper plate and 110 in the lower plate and server to support the postand join the upper plate 1304 to the lower plate of base 108.

In accordance with various embodiments presented herein, a cable railsupport post is produced by a process, the process comprising: providingan elongated member having one or more walls; flow-drilling a pluralityof holes in at least one wall of the elongated member, the holes spacedalong a length of the elongated member, where the flow-drilling of ahole increases the thickness of the wall in the vicinity of the hole;tapping the plurality of flow-drilled holes to produce a plurality ofthreaded receivers spaced along a length of the elongated member, theplurality of threaded receivers configured to receive cable railfittings; and joining a base support bracket to a lower end portion ofthe elongated member, the base support bracket configured to enable thecable rail support post to be fastened to a surface.

Further in accordance with embodiments described herein a method ofmanufacturing a cable rail support post is provided, the methodcomprising: providing an elongated member having one or more walls;providing a base support bracket; forming a plurality of threadedreceivers spaced along a length of the elongated member, a threadedreceiver of the plurality of threaded receivers produced by:flow-drilling a hole in a wall of the elongated member, where the flowdrilling increases the thickness of the wall in the vicinity of thehole; and tapping the flow-drilling hole, forming a plurality ofmounting holes in the base support bracket; and welding a base supportbracket to an end of the elongated member, where the threaded receiversare configured to receive rail fittings.

Also provided is a cable rail support post in accordance with thevarious embodiments described herein, the cable rail support postcomprising: an elongated member having one or more walls; a plurality ofthread receivers comprising tapped holes in at least one wall of theelongated member, the holes spaced along a length of the elongatedmember, the plurality of threaded receivers configured to receive cablerail fittings; and a base support bracket coupled to a lower end portionof the elongated member, the base support bracket configured to enablethe cable rail support post to be fastened to a surface and furtherconfigured to support a lower portion of a hollow decorative sleeveplaced over the support post, the base support post comprising one ormore raised platforms, a raised platform of the one or more raisedplatforms sized to engage an interior dimension of the lower portion ofthe hollow decorative sleeve.

The implementations of the present disclosure, described above, areintended to be examples only. Those of skill in the art can effectalterations, modifications and variations to the particular exampleembodiments herein without departing from the intended scope of thepresent disclosure. Moreover, selected features from one or more of theabove-described example embodiments can be combined to createalternative example embodiments not explicitly described herein.

The present disclosure may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. The describedembodiments are to be considered in all respects only as illustrativeand not restrictive. The scope of the disclosure is, therefore,indicated by the appended claims rather than by the foregoingdescription. All changes that come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

I claim:
 1. A railing post apparatus at least partially enclosed by aninterior of a decorative sleeve element on two or more sides, thedecorative sleeve element having a plurality of holes spaced along alength thereof that are positioned to be aligned with a plurality ofthreaded receivers to accommodate threaded end portions of one or morecable railing fittings passed through the plurality of holes of thedecorative sleeve element, the railing post apparatus comprising: asupport post having at least one wall, wherein the decorative sleeveelement is positioned about the support post before a cable is affixedto the support post; and a plurality of threaded receivers disposed inat least one wall of the support post, the threaded receivers comprisinga plurality of tapped, flow-drilled holes in at least one wall of thesupport post, the holes spaced along a length of the post and each ofthe threaded receivers configured to receive a threaded end portion of acorresponding cable rail fitting; wherein at least a portion of the atleast one wall has an increased thickness as a result of the pluralityof threaded receivers being formed by flow-drilling the support post,and wherein the plurality of holes in the decorative sleeve element arealigned with the plurality of threaded receivers of the support post toaccommodate cable rail fittings to pass therethrough.
 2. The apparatusas claimed in claim 1, further comprising: a sleeve support memberaffixed at a portion of the support post.
 3. The apparatus as claimed inclaim 2, where the sleeve support member is adapted to support thedecorative sleeve element.
 4. The apparatus as claimed in claim 2, wherethe sleeve support member has one or more holes thereon.
 5. Theapparatus as claimed in claim 2, where the sleeve support member has oneor more holes that correspond to holes of the decorative sleeve element.6. The apparatus as claimed in claim 2, where the sleeve support membercontacts at least three sides of the support post.
 7. The apparatus asclaimed in claim 1, further comprising: a base plate affixed to aportion of the support post.
 8. The apparatus as claimed in claim 1,where the decorative sleeve element is poly vinyl chloride.
 9. Theapparatus as claimed in claim 1, where the decorative sleeve element isfiberglass.
 10. The apparatus as claimed in claim 1, where thedecorative sleeve element is a non-structural material.
 11. Theapparatus as claimed in claim 1, where two or more walls of the supportpost have one or more holes.
 12. The apparatus as claimed in claim 1,where the support post is metal.
 13. A railing post apparatus at leastpartially enclosed by an interior of a decorative sleeve element on twoor more sides, the decorative sleeve element having a plurality of holesspaced along a length thereof that are positioned to be aligned with aplurality of threaded receivers to accommodate threaded end portions ofone or more cable railing fittings passed through the plurality of holesof the decorative sleeve element, the railing post apparatus comprising:a support post having at least one wall, wherein the decorative sleeveelement is positioned about the support post before a cable is affixedto the support post; a plurality of threaded receivers disposed in atleast one wall of the support post, the threaded receivers comprising aplurality of tapped holes in at least one wall of the support post, theholes spaced along a length of the post and each of the threadedreceivers configured to receive a threaded end portion of acorresponding cable rail fitting; wherein the plurality of holes in thedecorative sleeve element are aligned with the plurality of threadedreceivers of the support post to accommodate cable rail fittings to passtherethrough; and a sleeve support member affixed to a portion of thesupport post and adapted to support the decorative sleeve element, whenthe decorative sleeve element is affixed to the support post.
 14. Theapparatus as claimed in claim 13, further comprising: a base supportbracket coupled to a lower end portion of the support post, the basesupport bracket configured to enable the support post to be fastened toa surface and further configured for location inside the decorativesleeve element such that a gap is maintained between the decorativesleeve element and the support post.
 15. The apparatus as claimed inclaim 13, where the sleeve support member has one or more holes thereon.16. The apparatus as claimed in claim 13, where the sleeve supportmember has one or more holes that correspond to holes of the decorativesleeve element.
 17. The apparatus as claimed in claim 13, where thesleeve support member contacts at least three sides of the support post.18. The apparatus as claimed in claim 13, where two or more walls of thesupport post have one or more holes.
 19. The apparatus as claimed inclaim 13, where the support post is metal.